Product packaging

ABSTRACT

A tray device includes plastic material. The tray device further includes divided product compartments that separate multiple products. A top reinforced ridge surrounds the tray device. A perimeter upper trim is connected to the top reinforced ridge. The perimeter upper trim includes a surface that has a return towards a base of the tray device. The upper trim flexes upon wrapping the tray device with a sealing sheet.

BACKGROUND

Fresh foods packaged for shipping, distribution and sale. Packagingneeds to store goods and be sealed for maintaining freshness, keepingout contaminants, etc. Many times the products are packed on top of oneanother and side by side. Shipping of the packaged fresh foods tends tomove the packaged products causing abrasion to the sealing sheets of thepackaging, which allows excess air, dust/dirt, insects, etc. to enterthe product packaging.

SUMMARY

One embodiment of the invention comprises a tray device comprisingplastic material. The tray device further comprises a plurality ofdivided product compartments that separate multiple products. A topreinforced ridge surrounds the tray device. A perimeter upper trim isconnected to the top reinforced ridge. The perimeter upper trim includesa surface that has a return towards a base of the tray device. The uppertrim flexes upon wrapping the tray device with a sealing sheet.

Another embodiment of the invention comprises apparatus comprising: amold plate having a cavity for a plurality of divided productcompartments for molding a tray device and a plug assist portion. Acavity for a top reinforced ridge that surrounds the tray device. Acavity for a perimeter upper trim coupled to the cavity for the topreinforced ridge. The cavity for the perimeter upper trim comprises agroove in the mold plate for molding a surface that includes a returntowards a base of the tray device. The cavity for the perimeter uppertrim is coupled to a first vacuum through hole within the mold plate anda second vacuum through hole within the mold plate. The first throughhole and the second through hole are each coupled to a third vacuumthrough hole in the mold plate.

Yet another embodiment of the invention comprises an apparatus. Theapparatus comprises a corn cob tray device comprising plastic material.The corn cob tray device includes a plurality of cylindrical shapedproduct compartments that separate multiple corn produce products fromcoming into contact with one another. A top reinforced ridge surroundsthe corn cob tray device. A perimeter upper trim is coupled to the topreinforced ridge. The perimeter upper trim comprises a surface thatincludes a return towards a base of the corn cob tray device. The uppertrim flexes upon wrapping the corn cob tray device with a sealing sheetfor prevention of tearing the sealing sheet.

Other aspects and advantages of the present invention will becomeapparent from the following detailed description, which, when taken inconjunction with the drawings, illustrate by way of example theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments are illustrated by way of example, and not by way oflimitation, in the Figures of the accompanying drawings and in whichlike reference numerals refer to similar elements and in which:

FIG. 1 illustrates a perspective view of a single row product packagingdevice according to one embodiment of the invention;

FIG. 2 illustrates a perspective view of a single row product packagingdevice shown with exemplar corn products inserted into the device,according to one embodiment of the invention;

FIG. 3 illustrates a side view of the single row product packagingdevice shown in FIG. 2 according to one embodiment of the invention;

FIG. 4 illustrates a side view of multiple stacked single row productpackaging devices including exemplar corn products inserted into thestacked single row product packaging devices according to oneembodiment;

FIG. 5 illustrates a perspective view of multiple stacked single rowproduct packaging devices including exemplar corn products inserted intothe stacked single row product packaging devices according to oneembodiment;

FIG. 6 illustrates a perspective view of a double row product packagingdevice according to one embodiment of the invention;

FIG. 7 illustrates a perspective view of a double row product packagingdevice shown with exemplar corn products inserted into the deviceaccording to one embodiment of the invention;

FIG. 8 illustrates a side view of the double row product packagingdevice shown in FIG. 7 according to one embodiment of the invention;

FIG. 9 illustrates a side view of multiple stacked double row productpackaging devices including exemplar corn products inserted into thestacked double row product packaging devices according to oneembodiment;

FIG. 10 illustrates a perspective view of multiple stacked double rowproduct packaging devices including exemplar corn products inserted intothe stacked double row product packaging devices according to oneembodiment;

FIG. 11 illustrates a perspective view of a mold plate according to oneembodiment of the invention;

FIG. 12A illustrates a top view of the mold plate shown in FIG. 11according to one embodiment of the invention;

FIG. 12B illustrates a cross-sectional view of the mold plate shown inFIG. 12A along section A-A according to one embodiment of the invention

FIG. 12C illustrates a detailed view of B shown in FIG. 12B according toone embodiment of the invention;

FIG. 13 illustrates a close-up view of the mold plate shown in FIG. 11according to one embodiment of the invention;

FIG. 14 illustrates a cross-section view of a plug assist for the moldplate shown in FIG. 11 according to one embodiment of the invention; and

FIG. 15 illustrates a close-up view of the cross-section view shown inFIG. 14 according to one embodiment of the invention.

DETAILED DESCRIPTION

The following description is made for the purpose of illustrating thegeneral principles of the invention and is not meant to limit theinventive concepts claimed herein. Further, particular featuresdescribed herein can be used in combination with other describedfeatures in each of the various possible combinations and permutations.Unless otherwise specifically defined herein, all terms are to be giventheir broadest possible interpretation including meanings implied fromthe specification as well as meanings understood by those skilled in theart and/or as defined in dictionaries, treatises, etc.

The description may disclose several preferred embodiments of productpackaging, as well as operation and/or component parts thereof. Whilethe following description will be described in terms of corn cob productpackaging for clarity and to place the invention in context, it shouldbe kept in mind that the teachings herein may have broad application toall types of systems, devices and applications.

The embodiments relate to product packaging, and in particular to moldsand product packaging for corn products having specialized features forpreventing tearing of sealing sheets. One embodiment of the inventionprovides a tray device comprising plastic material. The tray devicefurther comprises a plurality of divided product compartments thatseparate multiple products. A top reinforced ridge surrounds the traydevice. A perimeter upper trim is connected to the top reinforced ridge.The perimeter upper trim includes a surface that has a return towards abase of the tray device. The upper trim flexes upon wrapping the traydevice with a sealing sheet.

FIG. 1 illustrates a perspective view of a single row product packagingdevice (or tray device) 100 according to one embodiment of theinvention. In one example, the product packaging device 100 may bemanufactured by a thermoforming, injection molding, or any equivalentforming processes. In one example the raw material may comprise a flatextruded sheet of recycled and recyclable polyethylene terephthalate(RPET) plastic resin, polypropylene (PP), PVC, polyethylene (PE),polystyrene (PS), etc. (e.g., recycled water bottles, soda bottles,etc.). In one embodiment of the invention, the product packaging device100 includes multiple (e.g., 4, 6, 8, etc.) curved or semi-cylindrical(e.g., partial cylindrical) shaped product dividing compartments 120. Inone example, the dividing compartments 120 separate corn cob produceproducts from contacting one another while packaged within the productpackaging device 100.

In one embodiment, the product packaging device 100 includes a topreinforced ridge 140 surrounding the product packaging device 100. Thetop reinforced ridge 140 includes strengthening ribs 130 that preventdeflection of the top reinforced ridge 140 upon wrapping the productpackaging device 100 with the sealing sheet (e.g., plastic sheeting,wrapping film, plastic wrap, perforated plastic wrap, shrink wrap, highdensity polyethylene, etc.). In one embodiment, a perimeter upper trimis formed with the top reinforced ridge 140. The perimeter upper trimincludes a surface 145 (FIG. 2) that has a return towards a base 150 (orbottom) of the product packaging device 100. In one example, the returnis thermoformed and has a thickness that is less than a thickness forall other tray device components of the product packaging device 100. Inone example, the lesser thickness of the return provides a feature thata sealing sheet avoids tearing from abrasion by having a greaterflexibility than other portions of the product packaging device 100.

An exterior surface of the base 150 is flat. The upper trim has athickness that provides for flexing upon the product packaging device100 being wrapped with a plastic sealing sheet. In one embodiment, theproduct packaging device 100 includes flat exterior side walls 110.

FIG. 2 illustrates a perspective view of a single row product packagingdevice 100 shown with exemplar corn cob produce products 210 insertedinto the product packaging device 100, according to one embodiment ofthe invention. As shown, corn cob produce products are each inserted totheir own dividing compartment 120, which holds the respective corn cobproduce product 210 in place. The corn cob produce products 210 arepacked closely together in the product packaging device 100, but do notcome in contact with one another due to the width of the upper ridge 125between each dividing compartment 120.

FIG. 3 illustrates a side view of the single row product packagingdevice 100 shown in FIG. 2 according to one embodiment of the invention.FIG. 4 illustrates a side view example 400 of multiple stacked singlerow product packaging devices 100 including exemplar corn cob produceproducts 210 inserted into the stacked single row product packagingdevices according to one embodiment. In one example, due to thecombination of the base 150 being flat, the reinforcing ribs 130, andthe placement of the corn cob products 210 in the dividing compartments120 for tightly packing corn cob products 210, multiple corn cob packedproduct packaging devices 100 are stackable with stability, and withoutdamaging the corn cob product products 210. FIG. 5 illustrates aperspective view of multiple stacked single row product packagingdevices 100 including exemplar corn cob produce products 210 insertedinto the stacked single row product packaging devices 100, according toone embodiment.

FIG. 6 illustrates a perspective view of a double row product packagingdevice 600 according to one embodiment of the invention. In one example,the product packaging device 600 may be manufactured by a thermoforming,injection molding, or any equivalent forming processes. In one examplethe raw material may comprise the same or similar materials as withproduct packaging device 100 (FIG. 1). In one embodiment of theinvention, the product packaging device 100 includes multiple (e.g., 8,etc.) curved or semi-cylindrical (e.g., partial cylindrical) shapedproduct dividing compartments 620. In one example, the dividingcompartments 620 separate corn cob produce products from contacting oneanother while packaged within the product packaging device 100 based onthe width of the upper ridge 625 between each dividing compartment 620and the gap or groove 626 between the two columns of dividingcompartments 620.

In one embodiment, the product packaging device 600 includes a topreinforced ridge 640 surrounding the product packaging device 600. Thetop reinforced ridge 640 includes strengthening ribs 630 that preventdeflection of the top reinforced ridge 640 upon wrapping the productpackaging device 600 with the sealing sheet (e.g., plastic sheeting,wrapping film, plastic wrap, perforated plastic wrap, shrink wrap, highdensity polyethylene, etc.). In one embodiment, a perimeter upper trimis formed with the top reinforced ridge 640. The perimeter upper trimincludes a surface 645 (FIG. 7) that has a return towards a base 650 (orbottom) (FIG. 8) of the product packaging device 600. In one example,the return is thermoformed and has a thickness that is less than athickness for all other tray device components of the product packagingdevice 600.

An exterior surface of the base 650 is flat. The upper trim has athickness that provides for flexing upon the product packaging device600 being wrapped with a plastic sealing sheet. In one embodiment, theproduct packaging device 600 includes flat exterior side walls 610.

FIG. 7 illustrates a perspective view of a double row product packagingdevice 600 shown with exemplar corn cob produce products 710 insertedinto the product packaging device 600, according to one embodiment ofthe invention. As shown, corn cob produce products 710 are each insertedto their own dividing compartment 620, which holds the respective corncob produce product 710 in place. The corn cob produce products 710 arepacked closely together in the product packaging device 600, but do notcome in contact with one another due to the width of the upper ridge 625between each dividing compartment 620 and the gap or groove 626.

FIG. 8 illustrates a side view of the double row product packagingdevice 600 shown in FIG. 7 according to one embodiment of the invention.FIG. 9 illustrates a side view example 900 of multiple stacked singlerow product packaging devices 600 including exemplar corn cob produceproducts 710 inserted into the stacked double row product packagingdevices according to one embodiment. In one example, due to thecombination of the base 650 being flat, the reinforcing ribs 630, andthe placement of the corn cob products 710 in the dividing compartments620 for tightly packing corn cob products 710, multiple corn cob packedproduct packaging devices 600 are stackable with stability, and withoutdamaging the corn cob product products 710. FIG. 10 illustrates aperspective view of multiple stacked double row product packagingdevices 600 including exemplar corn cob produce products 710 insertedinto the stacked single row product packaging devices 600, according toone embodiment.

FIG. 11 illustrates a perspective view of a mold plate system 1100according to one embodiment of the invention. In one embodiment, themold plate system 1100 includes a metal (e.g., aluminum) mold plate1110, a first corn cob tray cavity 1120 for either single row (notshown) or double row corn cob dividing compartments, a second corn cobtray cavity 1125, a plug assist 1130 and a plug assist mounting holes1131.

FIG. 12A illustrates a top view of the mold plate system 1100 shown inFIG. 11 according to one embodiment of the invention. In one example,the line A-A is shown across the middle/center of the mold plate 1110.FIG. 12B illustrates a cross-sectional view of the mold plate system1100 shown in FIG. 12A along section A-A according to one embodiment ofthe invention. As shown, the internal view of the mold plate 1230includes the view of the plug assist 1210 and the view of the corn tray1220. The circle referenced as “B” is enlarged in FIG. 12C. As shown inFIG. 12C, a detailed view of the circle “B” shown in FIG. 12B includesthe view of the plug assist 1210, the view of the corn tray 1220, themold plate 1230, a large drilled vacuum hole 1231, a vacuum groove 1232,small vacuum holes 1233, and air gap 1234 between the bottom of the moldplate 1110 and the plug assist 1130.

FIG. 13 illustrates a close-up view of the mold plate 1110 of the moldplate system 1100 shown in FIG. 11, according to one embodiment of theinvention. The details of the mold plate 1110 including the plug assist1130, the plug assist mounting holes 1131 and the first corn cob traycavity 1120 for corn cob dividing compartments are shown in the close-upview.

FIG. 14 illustrates a cross-section view of a plug assist 1130 for themold plate 1110 of the mold plate system 1100 shown in FIG. 11,according to one embodiment of the invention. In one embodiment, themold plate 1110 includes a mold portion for a return 1420 that extendstowards a base of the tray portion and has an extension that isperpendicular to the top ridge 1510 (FIG. 15). In one example, thereturn 1420 prevents plastic wrap film from being cut due to abrasion.In on embodiment, the return 1420. In one embodiment, the space 1410provides for a vacuum to be created for the mold plate system 1100.

FIG. 15 illustrates a close-up view of the cross-section view shown inFIG. 14 according to one embodiment of the invention. In one embodiment,the mold plate 1110 includes a top ridge 1510 opposite the return 1420.In one example, the return 1420 is formed by milling an extra groove inthe mold plate 1110. In one embodiment, grooves 1520 are milled intowall 1521 of the mold plate 1110 for forming strengthening ribs 130(FIG. 1).

In the description above, numerous specific details are set forth.However, it is understood that embodiments of the invention may bepracticed without these specific details. For example, well-knownequivalent components and elements may be substituted in place of thosedescribed herein, and similarly, well-known equivalent techniques may besubstituted in place of the particular techniques disclosed. In otherinstances, well-known structures and techniques have not been shown indetail to avoid obscuring the understanding of this description.

Reference in the specification to “an embodiment,” “one embodiment,”“some embodiments,” or “other embodiments” means that a particularfeature, structure, or characteristic described in connection with theembodiments is included in at least some embodiments, but notnecessarily all embodiments. The various appearances of “an embodiment,”“one embodiment,” or “some embodiments” are not necessarily allreferring to the same embodiments. If the specification states acomponent, feature, structure, or characteristic “may”, “might”, or“could” be included, that particular component, feature, structure, orcharacteristic is not required to be included. If the specification orclaim refers to “a” or “an” element, that does not mean there is onlyone of the element. If the specification or claims refer to “anadditional” element, that does not preclude there being more than one ofthe additional element.

While certain exemplary embodiments have been described and shown in theaccompanying drawings, it is to be understood that such embodiments aremerely illustrative of and not restrictive on the broad invention, andthat this invention not be limited to the specific constructions andarrangements shown and described, since various other modifications mayoccur to those ordinarily skilled in the art.

What is claimed is:
 1. A tray device for product packaging comprising: atray device comprising plastic material, the tray device including: aplurality of divided product compartments that separate multipleproducts; a top reinforced ridge surrounding the tray device; and aperimeter upper trim coupled to the top reinforced ridge, the perimeterupper trim comprises a surface that includes a return towards a base ofthe tray device, the upper trim flexes upon wrapping the tray devicewith a sealing sheet.
 2. The tray device of claim 1, wherein the plasticmaterial comprises one of: recycled polyethylene terephthalate (RPET),polypropylene (PP), polyethylene (PE) or polystyrene (PS).
 3. The traydevice of claim 2, wherein the tray device further comprises flatexterior side walls.
 4. The tray device of claim 2, wherein an exteriorsurface of the base is flat.
 5. The tray device of claim 4, wherein eachof the divided product compartments has a curved shape and preventsadjacent products from contacting one another.
 6. The tray device ofclaim 4, wherein each of the divided product compartments has asemi-cylindrical shape.
 7. The tray device of claim 6, wherein the topreinforced ridge comprises strengthening ribs that prevent deflection ofthe top reinforced ridge upon wrapping the tray device with the sealingsheet.
 8. The tray device of claim 4, wherein the tray device isstackable with other tray devices.
 9. The tray device of claim 8,wherein the return is thermoformed and has a thickness that is less thana thickness for all other components of the tray device.
 10. The traydevice of claim 1, wherein the tray device formed by thermoforming orinjection molding, the plastic material comprises recycled or recyclablematerial, and the plurality of divided product compartments comprise oneof a single row of divided corn produce product compartments or doublerows of divided corn produce product compartments.
 11. An apparatuscomprising: a mold plate having a cavity for a plurality of dividedproduct compartments for molding a tray device, and a plug assistportion; a cavity for a top reinforced ridge that surrounds the traydevice; a cavity for a perimeter upper trim coupled to the cavity forthe top reinforced ridge, the cavity for the perimeter upper trimcomprises a groove in the mold plate for molding a surface that includesa return towards a base of the tray device, wherein the cavity for theperimeter upper trim is coupled to a first vacuum through hole withinthe mold plate and a second vacuum through hole within the mold plate,the first through hole and the second through hole are each coupled to athird vacuum through hole in the mold plate.
 12. The apparatus of claim11, wherein the third through hole has a larger volume in the mold platethan each of the first through hole and the second through hole.
 13. Theapparatus of claim 12, wherein the groove in the mold plate isconfigured for forming a flexible surface coupled to the top reinforcedridge of the tray device.
 14. The apparatus of claim 13, wherein themold plate receives molding material comprising one of: recycledpolyethylene terephthalate (RPET), polypropylene (PP), polyethylene (PE)or polystyrene (PS).
 15. The apparatus of claim 14, wherein the moldplate includes a cavity for forming flat exterior side walls for thetray device, each divided product compartment has a curved shape and isconfigured for preventing adjacent produce products from contact withone another, and each of the divided product compartments has asemi-cylindrical shape.
 16. The apparatus of claim 15, wherein theflexible surface is thermoformed for having a thickness that is lessthan a thickness for all other components of the tray device.
 17. Theapparatus of claim 11, wherein the plurality of divided productcompartments comprise one of a single row of divided corn produceproduct compartments or double rows of divided corn produce productcompartments.
 18. An apparatus comprising: a corn cob tray devicecomprising plastic material, the corn cob tray device including: aplurality of semi-cylindrical shaped product compartments that separatemultiple corn produce products from coming into contact with oneanother; a top reinforced ridge surrounding the corn cob tray device;and a perimeter upper trim coupled to the top reinforced ridge, theperimeter upper trim comprises a surface that includes a return towardsa base of the corn cob tray device, the upper trim flexes upon wrappingthe corn cob tray device with a sealing sheet for prevention of tearingthe sealing sheet.
 19. The apparatus of claim 18, wherein: the plasticmaterial comprises one of: recycled polyethylene terephthalate (RPET),polypropylene (PP), polyethylene (PE) or polystyrene (PS); the topreinforced ridge comprises strengthening ribs that prevent deflection ofthe top reinforced ridge upon wrapping the corn cob tray device with thesealing sheet; the return is thermoformed and has a thickness that isless than a thickness for all other components of the corn cob traydevice; and the corn cob tray device formed by thermoforming orinjection molding.
 20. The apparatus of claim 19, wherein the corn cobtray device further comprises flat exterior side walls, wherein anexterior surface of the base is flat.